2004 Honda Element

From 2000 through 2017, Takata produced millions of air bag inflators using two types of phase-stabilized ammonium nitrate ("PSAN") propellant -- propellant 2004 and propellant 2004L. After prolonged exposure to high temperature cycles and humidity, inflators using propellant 2004 can degrade, causing the propellant to burn too quickly when ignited. The rapid burning can cause the inflator to rupture during deployment, potentially causing serious or even fatal injury to vehicle occupants. See 2016 Blomquist Report at www.nhtsa.gov/sites/nhtsa.gov/files/documents/expert_report-hrblomquist.pdf.Consequently, all frontal inflators using propellant 2004 that do not contain a "desiccant" (a substance that traps and holds moisture) in US vehicles are under recall. These "non-desiccated" inflators either have been or are required to be replaced.In some cases, the remedy part for these recalled inflators was, or will be, an inflator using either propellant 2004 or 2004L that does contain a desiccant. None of these "desiccated" remedy parts (which were installed in older model year vehicles) are currently under recall for a degradation concern. Certain subsets of desiccated PSAN inflators using propellant 2004 for use as original equipment, however, have been recalled for a degradation concern. All Takata inflators produced with propellant 2004L contain desiccant, and none of these desiccated inflators using propellant 2004L are under recall for a degradation concern. There have been no reported field ruptures in any non-recalled desiccated PSAN inflators.It is understood that desiccants fully saturate at some threshold, at which point any additional moisture will not be captured. This means the degradation process observed in non-desiccated inflators using propellant 2004 may also occur in non-recalled desiccated inflators using propellant 2004, assuming additional moisture enters the inflator and high temperature cycling occurs. Based on available information, desiccant saturation can occur within the first five years in the worst environments, and the time required for full saturation is affected by multiple factors. While no present safety risk has been identified, further work is needed to evaluate the future risk of non-recalled desiccated inflators using propellant 2004.Three entities -- Takata (now known as TK Global), the Independent Testing Coalition, and Exponent -- have been studying the long-term behavior of Takata desiccated PSAN inflators using propellant 2004L (as well as 2004) in the presence of moisture and temperature cycling. The research efforts, which include development of predictive modeling techniques and field sample analysis, are ongoing. To date, none of the researchers have identified field evidence showing that propellant 2004L is undergoing a degradation process that leads to aggressive deployment and potential rupture. However, the time in service of such inflators remains short compared to that of the inflators using propellant 2004. Further study is needed to assess the long-term safety of desiccated inflators using propellant 2004L.The Office of Defects Investigation is opening this investigation to examine whether a safety defect related to propellant degradation exists in non-recalled desiccated PSAN frontal inflators manufactured by Takata. This investigation will require extensive information on Takata production processes and surveys of inflators in the field. Lists of recall actions that may have used desiccated PSAN inflators as remedy parts, as well as the makes and models originally manufactured with them, is available with the downloadable version of this document (see nhtsa.gov/recalls?nhtsaId=EA21002 -- note this information is subject to change/revision as the investigation proceeds). This investigation does not supersede EA15-001, which remains open.

The Office of Defects Investigation (ODI) opened PE14-016 in June 2014 based on six inflator rupture incidents involving consumer owned vehicles produced by five vehicle manufacturers.All six vehicles were operated in Florida or Puerto Rico at the time of the rupture and for the majority of their service life, and were equipped with inflators produced by Takata, a tier-one supplier of automotive air bag systems.During the course of PE14-016, ODI determined that five additional vehicle manufacturers used inflators of a similar design and vintage also supplied by Takata. No evidence of field failures was found in vehicles produced by these five additional manufacturers.Nonetheless, at ODI's insistence, all 10 vehicle manufacturers initiated a regional recall within approximately two weeks of the opening of the investigation.The regions recalled initially included Florida, Puerto Rico, Hawaii, and the U.S. Virgin Islands, areas with high absolute humidity and climatic conditions believed to be a significant factor in the inflator ruptures.As part of the recall actions, inflators removed from remedied vehicles are to be returned to Takata for testing.Takata's initial test results on passenger inflators from remedied vehicles indicated a much higher than anticipated rupture frequency for inflators returned from Florida.Accordingly ODI requested all 10 manufacturers expand the regional recalls for passenger inflators to include other geographic areas where high absolute humidity conditions exist, including the Gulf States and other coastal areas.Takata's testing of the passenger inflators to date continues to indicate this geographic area as having the highest risk, with no ruptures occurring from inflators returned from outside the expanded recall regions.During PE14-016 four additional passenger inflator field events occurred, all in vehicles from the same expanded geographic region.Also during PE14-016 four additional driver inflator field events occurred including two in vehicles from regions not known for high absolute humidity, specifically California and North Carolina.Accordingly, ODI requested all five of the affected vehicle manufacturers currently using the subject Takata driver inflators expand to nationwide recalls.Significantly, neither of the affected vehicle manufacturers or Takata provided any explanation to account for these two driver air bag inflator ruptures outside the area of high absolute humidity.Takata testing of returned driver inflators indicates a lower rupture frequency as compared to passenger inflator testing.All test ruptures reported by Takata to date have occurred on inflators returned from high absolute humidity areas.The investigation now includes all manufacturers and vehicles known to be affected at this time.ODI's investigation will focus on, among other things, root cause analysis, other potential defect consequences, identification of affected vehicles scope, and adequacy of the remedy.The five ODI reports cited above can be reviewed online at http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10537899, 10568848, 10585224, 10605877, 10651492

The Office of Defects Investigation (ODI) opened PE14-016 in June 2014 based on six inflator rupture incidents involving consumer owned vehicles produced by five vehicle manufacturers.All six vehicles were operated in Florida or Puerto Rico at the time of the rupture and for the majority of their service life, and were equipped with inflators produced by Takata, a tier-one supplier of automotive air bag systems.During the course of PE14-016, ODI determined that five additional vehicle manufacturers used inflators of a similar design and vintage also supplied by Takata. No evidence of field failures was found in vehicles produced by these five additional manufacturers.Nonetheless, at ODI's insistence, all 10 vehicle manufacturers initiated a regional recall within approximately two weeks of the opening of the investigation.The regions recalled initially included Florida, Puerto Rico, Hawaii, and the U.S. Virgin Islands, areas with consistently high absolute humidity and climatic conditions believed to be a significant factor in the inflator ruptures.As part of the recall actions, inflators removed from remedied vehicles are to be returned to Takata for testing.Takata's initial test results on passenger inflators from remedied vehicles indicated a much higher than anticipated rupture frequency for inflators returned from Florida.Accordingly, ODI requested all 10 manufacturers expand the regional recalls for passenger inflators to include other geographic areas where high absolute humidity conditions exist, including the Gulf States and other coastal areas.Takata's testing of the passenger inflators to date continues to indicate this geographic area as having the highest risk, with no ruptures occurring from inflators returned from outside the expanded recall regions.During PE14-016, four additional passenger inflator field events occurred, all in vehicles from the same expanded geographic region.Also during PE14-016, four additional driver inflator field events occurred including two in vehicles from regions not known for high absolute humidity, specifically California and North Carolina.Accordingly, ODI requested all five of the affected vehicle manufacturers currently using the subject Takata driver inflators expand to nationwide recalls.Significantly, neither of the affected vehicle manufacturers or Takata provided any explanation to account for these two driver air bag inflator ruptures outside the area of high absolute humidity.Takata testing of returned driver inflators indicates a lower rupture frequency as compared to passenger inflator testing.All test ruptures reported by Takata to date have occurred on inflators returned from high absolute humidity areas.The PE is now closed/upgraded to an Engineering Evaluation (EA15-001) to include all manufacturersand vehicles known to be affected at this time.ODI's EA investigation will focus on, among other things, root cause analysis, other potential defect consequences, identification of affected vehicles scope, and adequacy of the remedy.The recalls related to this PE are: 14V343, 14V344, 14V348, 14V351, 14V353, 14V655, 14V700, 14V701, 14V752, 14V763, 14V770, 14V773, 14V787, 14V802 and 14V817.The number of vehicles affected are an estimate since some vehicles may have both the driver and passenger side inflators recalled. The five ODI reports cited above can be reviewed online at http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10537899, 10568848, 10585224, 10605877, 10651492

On August 4, 2010, American Honda Motor Co. (Honda) submitted a Defect Information Report (DIR) to NHTSA regarding a ignition interlock defect in approximately 384,220 model year (MY) 2003 Honda Accord and Civic and MY 2003 and 2004 Honda Element vehicles with automatic transmissions (Recall 10V-364).In a September 22, 2010 supplemental DIR, Honda expanded the scope of the recall population based on manufacturing and complaint data.The total population for the complete recall is approximately 551,498 vehicles.The information listed in this closing report refers only to the subject vehicles, MY 2003 Accords with automatic transmissions.According to Honda's DIR, Under certain conditions the interlock lever of the ignition switch may unexpectedly deform, which can allow the interlock function of a vehicle with an automatic transmission to be defeated if the driver does not follow the typical shut-down procedure of shifting the gear selector to the Park position before rotating the ignition key to the off position. Removal of the ignition key when the gear selector of a vehicle with an automatic transmission has not been shifted to the Park position can allow the vehicle to roll away, increasing the risk of a crash.Honda's dealers will be instructed to inspect the ignition interlock switch and, if necessary, replace the original interlock pin and lever within the ignition switch and replace them with new, redesigned parts.This investigation is closed.

On 722 2024 dealer try to replace a defective seatbelt buckle could not do the repair could not get a replacement from Honda SRS light stays on so that if the vehicle is in an accident, the airbags will not deploy. Have been waiting on this partfor a very long time. Have no information from Honda when this will be available.

NHTSA ID

11711421

Incident

Jul 24, 2024

Trailing arm mount rotting out from rust

NHTSA ID

11674826

Incident

Jun 19, 2025

my control arm mount and frame of my element is rusted out, it is an ongoing problem with the honda element as i am seeing a lot of people online with similar issues. if this fails, it could put people at risk, i also see other elements on the road with a camber'd out back tire on the driver side. i believe these wheels would fall into the car causing an accident. there are no warning lights that pop on, this is hard to get a look at until you get under the vehicle. they have done recalls on this exact problem in canada already, we need it here as well in the usa. the crv has also had the same issues and was given a recall in usa. i am very concerned with the amount of these cars on the road that many do not know the danger they are in.

NHTSA ID

11670614

Incident

Jul 1, 2025

Just like the same era's Honda CR-V (the Honda Element's sibling car with many of the same components), the undercarriage rust on my vehicle is excessive: as described in the same era Honda CR-V's NHTSA Recall (23V-228). Large sections of my car’s rear frame are completely missing, and as shown in the photographs even the rear bumper fell off because of all of the rust. Just like with the CR-V, a recall for the rear frame corrosion first occurred in Canada and then in the US: see NHTSA Recall 23V-228’s chronology. The Honda Element's Canadian recall is as follows: "Transport Canada Recall - 2021024 – HONDA". As of today, there is no NHTSA recall for rear frame corrosion for Honda Elements. I am submitting this complaint for this car now, and also contemporaneously am submitting complaints under different VINs for my other Elements with rust problems: every Honda Element that I have ever owned, even one that had spent its entire 14 year life as a New Mexico, Arizona, and Texas car has had rust problems. In other words, no matter what environment these Elements (which were made for the model years 2003-2011) are in, they corrode right away (within any factory warranties), and eventually become dangerous.

NHTSA ID

11666870

Incident

Jun 13, 2025

The contact owns a 2004 Honda Element. The contact stated that the vehicle was repaired under an unknown recall related to the seat belts; however, the seat belt retractor was repaired incorrectly and was installed backward. The local dealer was not contacted due to new ownership. The vehicle was not diagnosed or repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 166,000.

NHTSA ID

11624195

Incident

Oct 11, 2011

Mileage

166,000 mi

The trailer arm rusted at the mount. I was told it was not safe to drive. I have learned that this is a common problem with this vehicle and Honda has issued a recall in Canada, but not the USA. I also learned that there is a similar issue with I believe the Honda CRV and that has been in recall from Honda in I believe both Canada and the US. I found a place to do the repair and he said he has seen a lot worse than mine and has done many of these repairs.. The total repair cost is $1500. I also learned that due to its design water gets trapped in the mount and causes the rust, which sounds definitely like a design flaw. The repair entails fabrication a whole new mount for the trailer arm. I discovered it on June 7th when I was doing some under body clean up.

NHTSA ID

11600578

Incident

Jul 7, 2024

The rear left trailing arm mounting point is completely corroded through, making the car unsafe to drive. If it were to fall off during driving the chances of it creating an accident are high. There are many other Elements with this specific spot rusting through.

NHTSA ID

11590452

Incident

May 23, 2024

● The area of the body that serves as the forward mounting point for the rear driver-side trailing arm has completely rusted though. At this mounting point, the trailing arm mounting bracket has become entirely separated from the body leaving only one bolt securing the trailing arm to the body. This is the same issue for which these vehicles have been recalled in Canada. Yes, the vehicle is available for inspection upon request. ● Continuing to operate the vehicle in this condition presents the possibility of catastrophic failure of the trailing arm mount, resulting in loss of control of the vehicle, endangering the lives of those in and outside of the vehicle. ● No, I have not taken the vehicle to a dealer or service center. ● No the vehicle/component has not been inspected by the manufacturer, police, or insurance representative. ● No warning lamps, messages, or other symptoms prior to the appearance of the problem on [XXX]. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11588955

Incident

May 12, 2024

Service Bulletin - Warranty Extension: Customer Support Program For Front Passenger's Airbag Inflator.

"Service Bulletin - There are several A/C leak detection tools available. -Refrigerant Gas Leak Detector -Ultrasonic Leak Detector -Leak Dye"

Service Bulletin - This bulletin is a notification of a class action settlement relating to airbag inflators. American Honda is offering a Customer Support Program (Warranty Extension) to cover any manufacturing defects in the replacement front passenger's airbag inflator only.

Service Bulletin - This bulletin is a notification of a class action settlement relating to airbag inflators. American Honda is offering a Customer Support Program (Warranty Extension) to cover any manufacturing defects in the replacement driver's airbag inflator only.

Service bulletin - This bulletin is a notification of a class action settlement relating to airbag inflators. American Honda is offering a Customer Support Program (Warranty Extension) to cover any manufacturing defects in the replacement front passengers airbag inflator only.

Service bulletin - This bulletin is a notification of a class action settlement relating to airbag inflators. American Honda is offering a Customer Support Program (Warranty Extension) to cover any manufacturing defects to the replacement driver's airbag inflator only.